US3834964A - Processing of a multiplicity of webs to enhance the manufacture of multicomponent laminates - Google Patents
Processing of a multiplicity of webs to enhance the manufacture of multicomponent laminates Download PDFInfo
- Publication number
- US3834964A US3834964A US00298212A US29821272A US3834964A US 3834964 A US3834964 A US 3834964A US 00298212 A US00298212 A US 00298212A US 29821272 A US29821272 A US 29821272A US 3834964 A US3834964 A US 3834964A
- Authority
- US
- United States
- Prior art keywords
- webs
- impregnated
- sheet
- laminates
- resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/08—Impregnating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/028—Paper layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/12—Paper, e.g. cardboard
- B32B2317/122—Kraft paper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2451/00—Decorative or ornamental articles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1084—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing of continuous or running length bonded web
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31942—Of aldehyde or ketone condensation product
- Y10T428/31949—Next to cellulosic
- Y10T428/31964—Paper
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31942—Of aldehyde or ketone condensation product
- Y10T428/31949—Next to cellulosic
- Y10T428/31964—Paper
- Y10T428/31967—Phenoplast
Definitions
- Decorative laminates generally contain a plurality of laminae which are heat and pressure consolidated to form a unitary structure.
- the surface sheet is usually a decorative sheet which may be solid in color or may carry a decorative design thereon such as a wood-grain print, a floral pattern or geometric figures.
- the decorative sheet is impregnated with a noble thermosetting resin which does not undergo any significant color deterioration during the consolidation step during which it is converted to the thermoset state.
- the impregnated decorative sheet is then superimposed over one or more core sheets which are generally kraft paper sheets, flakeboard etc. When using sheets, they usually have previously been impregnated with a phenolic thermosetting resin which is also converted to the thermoset state during heat and pressure consolidation.
- the number of core sheets can be varied very substantially from one or two sheets to as many as nine or more depending upon the desired thickness of the ultimate laminate.
- an overlay sheet is superimposed thereover, the overlay sheet generally being a fine quality alphacellulose paper sheet impregnated with the same class of noble thermosetting resin used to impregnate the decorative sheet. After heat and pressure consolidation, the overlay sheet becomes transparentized so as to render the decorative sheet readily observed.
- the individual sheets are then manually assembled into packs in superimposed relationship from top to bottom as follows: a release sheet; an overlay sheet; a decorative sheet; sufficient core sheets to impart the desired thickness to the laminate; and a back release sheet. These assemblies are then piled in a face-to-face relationship in stacks of thirty or more and the entire bundle is consolidated into thirty or more laminates.
- my novel process comprises simultaneously impregnating a plurality of webs with an impregating material and then preferably, drying the group of webs such as by passing them through a drying or baking oven to remove volatiles or otherwise set the materials.
- my novel process comprises impregnating two or more webs, either identical or diiferent in character and appearance, simultaneously with an impregnant material in a resin bath or zone and preferably subsequently simultaneously drying the so impregnated webs to remove volatiles or advance the cure thereof.
- any number of webs can be treated accordingly to my novel process with a range of 2-9 being preferred and the webs can be treated separately or in conjunction with one another. That is to say, two or more webs can be individually unrolled and impregnated in the same resin tank over two sets of rollers or the webs can be mated together in superimposed, overlying relationship before or during impregnation over the same set of rollers.
- types of webs which may be treated include kraft paper, a-cellulose paper, bleached sulfite, fibrillated acrylic decor sheets, linen, canvas, fiberglass, and the like.
- Useful impregnating resins or coatings include melamine-formaldehyde resins, urea-formaldehyde resins, epoxies, polyesters etc. see U.S. 2,197,357, hereby incorporated herein by reference. Phenolic resins, generally recognized by those skilled in the art, can also be used in my novel process.
- the impregnated webs are then preferably dried. They can be dried in the same condition i.e. mated or apart, or they can be subsequently mated and dried if impregnated apart or separated and dried if impregnated mated. Also, a plurality of webs may be treated mated with the impregnating material and one or more may be impregnated separately but simultaneously. The same is true of the drying operation. It is only critical that the same resin zone, bath etc. be used.
- Example 1 Two continuous alpha-cellulose overlay webs of 29 pounds basis weight (3,000 sq. ft.) of the same width are unwound simultaneously from two mill rolls each mounted on the unwind stand of a conventional material treater. The two webs are mated, one atop the other, and immersed in an aqueous melamine-formaldehyde resin solution, metering techniques being employed to control resin pick-up of each Web at 65%. The resultant impregnated web composite is then passed through a conventional drying oven at about 275 F., cut to size and stacked at the dry end. The resultant overlay sheets are easily separated and are obtained in a desirable treated condition with a uniform balance of dried resin being obtained in each ply of paper.
- the efficiency gain of the process is a 50-70% increase in the productive capacity of the unit when handling the two webs as against the handling of one web equal in weight to one of the webs handled in the composite. Foreign matter pick-up in the two web process is half that of the single web run.
- Example 2 Two webs, one an alpha-cellulose overlay sheet and the other a printed, opaque, pigmented pattern sheet are impregnated and dried as set forth in Example 1.
- the pattern sheet picks up 40% resin.
- the resultant cut, stacked and treated sheets are not only obtained in a desirable treated condition at an increased through-put for the treating unit as against handling the same webs independently, but the sheets are already interleafed in the order required to prepare a protected surface, printed pattern, decorative panel in a subsequent colating and heat and pressure consolidating operation.
- Example 3 Printed decorative paper is processed as described in Example 1, above, however the rolls of material feeding the treating llBiL are of reversed face resulting in the cut plies at the end of the drier being alternately face upface down.
- the results of the impregnation and drying are as described in Example 1 except that the pick-up recorded is 40%.
- the subsequent step of manually flipping the pattern sheet over in colating press build-ups where both faces of stainless steel plates are used in obtaining high gloss or textured surface decorative laminates is eliminated. Not only are the previously mentioned efficiency and cleanliness features obtained, but a substantial reduction in handling scraps is realized.
- Example 4 The procedure of Example 1 is again followed except that two rolls of kraft sheet of 129 pounds basis weight (3000 sq. ft.) are unrolled and passed individually through the material treater which has been fitted with a series of two roller units and filled with phenolic resin. The sheets each experience a pick-up of 30%. The drying oven is equipped with sheet separators. The efficiency gain in the productive capacity of the process is 63%.
- Example 5 The procedure of Example 1 is again followed except that four overlay webs are individually impregnated, dried and cut as disclosed therein.
- the resin treater is equipped with a series of four rollers and the oven is fitted with a sufficient number of sheet separators to keep the webs apart. Again an increase in material handling efficiency is realized.
- Example 6 The procedure of Example 1 is again followed except that a commercially available polyester resin is used as a substitute for the melamine/formaldehyde resin thereof. Similar results are achieved.
- Example 1 The procedure of Example 1 is again followed except the webs are separated after impregnation and dried separately.
- Example 8 The procedure of Example 4 is again followed except that the two Webs are mated in a superimposed overlying relationship after impregnation and dried as such.
- a process for the production of a decorative laminate which comprises superimposing from 2-9 cellulosic webs in an overlaying relationship, simultaneously impregnating the resultant superimposed, overlaying cellulosic webs by passing them into a resin bath containing a melamine/ formaldehyde or phenol/formaldehyde-resin, drying the resultant, impregnated, superimposed webs as such to remove solvent but only partially cure said resin, cutting said impregnated webs into sheets and heat and pressure consolidating said webs, in conjunction with other components, into a decorative laminate.
Landscapes
- Laminated Bodies (AREA)
Abstract
Description
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US00298212A US3834964A (en) | 1972-10-17 | 1972-10-17 | Processing of a multiplicity of webs to enhance the manufacture of multicomponent laminates |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US00298212A US3834964A (en) | 1972-10-17 | 1972-10-17 | Processing of a multiplicity of webs to enhance the manufacture of multicomponent laminates |
Publications (1)
Publication Number | Publication Date |
---|---|
US3834964A true US3834964A (en) | 1974-09-10 |
Family
ID=23149520
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US00298212A Expired - Lifetime US3834964A (en) | 1972-10-17 | 1972-10-17 | Processing of a multiplicity of webs to enhance the manufacture of multicomponent laminates |
Country Status (1)
Country | Link |
---|---|
US (1) | US3834964A (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4062711A (en) * | 1975-12-03 | 1977-12-13 | Davis R Elbert | Method for forming fiberglass-resin laminate with permanent indicia pattern |
FR2391071A1 (en) * | 1977-05-17 | 1978-12-15 | Held Kurt | PROCESS AND INSTALLATION FOR THE CONTINUOUS MANUFACTURING OF LAMINATES |
US4690721A (en) * | 1983-07-06 | 1987-09-01 | Santrade Ltd. | Apparatus and process for the production of multilayer laminated plates |
US4713138A (en) * | 1984-12-26 | 1987-12-15 | Nevamar Corporation | Method of producing abrasion-resistant decorative laminate |
-
1972
- 1972-10-17 US US00298212A patent/US3834964A/en not_active Expired - Lifetime
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4062711A (en) * | 1975-12-03 | 1977-12-13 | Davis R Elbert | Method for forming fiberglass-resin laminate with permanent indicia pattern |
FR2391071A1 (en) * | 1977-05-17 | 1978-12-15 | Held Kurt | PROCESS AND INSTALLATION FOR THE CONTINUOUS MANUFACTURING OF LAMINATES |
US4690721A (en) * | 1983-07-06 | 1987-09-01 | Santrade Ltd. | Apparatus and process for the production of multilayer laminated plates |
US4713138A (en) * | 1984-12-26 | 1987-12-15 | Nevamar Corporation | Method of producing abrasion-resistant decorative laminate |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US4940503A (en) | Process for the production of an abrasion resistant decorative thermosetting laminate | |
US3215579A (en) | Process for releasing laminates | |
US6106654A (en) | Process for the manufacturing of a decorative thermo-setting plastic laminate | |
DE69713572T2 (en) | A METHOD FOR PRODUCING A DECORATIVE COATING | |
US6375777B1 (en) | Process for the production of a thermosetting laminate | |
US6517935B1 (en) | Process for the production of a floor strip | |
US6896971B2 (en) | System and method for two sided sheet treating | |
KR100259684B1 (en) | Method of Coating Melamine Resin on Laminating Paper | |
DE102007015969B4 (en) | Method for producing a building board | |
DE2523670B2 (en) | Process for the continuous production and simultaneous coating of chipboard, which is covered with at least one cover layer made of synthetic resin-impregnated paper | |
JPH0213624B2 (en) | ||
EP2349717B1 (en) | Method for producing a sheet and subsequently produced sheet | |
NO156282B (en) | PROCEDURE FOR CONTINUOUS PREPARATION OF A MULTILAYER PLATE. | |
US3834964A (en) | Processing of a multiplicity of webs to enhance the manufacture of multicomponent laminates | |
JPS6111787B2 (en) | ||
US4263073A (en) | Process for releasing laminates | |
DE3916099A1 (en) | METHOD FOR THE PRODUCTION OF DECORATIVE LAYERED COMPRESSION PLATES | |
DE102013112275B4 (en) | Method for producing a decorative laminate | |
US20240025144A1 (en) | Method and System For Producing Coated Chipboard Having A Functional Surface | |
JP2543098B2 (en) | Laminated board manufacturing method | |
EP3287277B1 (en) | Laminated material | |
WO2024146756A1 (en) | Method for producing a laminate comprising at least one kraft paper layer and at least one other paper layer | |
US3629031A (en) | Method of manufacturing a compound laminar material | |
JPH0114025B2 (en) | ||
JPS59209863A (en) | Manufacture of decorative board |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: FORMICA TECHNOLOGY INC. Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:FORMICA CORPORATION;REEL/FRAME:004829/0161 Effective date: 19880129 Owner name: FORMICA TECHNOLOGY INC.,STATELESS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:FORMICA CORPORATION;REEL/FRAME:004829/0161 Effective date: 19880129 |
|
AS | Assignment |
Owner name: CANADIAN IMPERIAL BANK OF COMMERCE Free format text: SECURITY INTEREST;ASSIGNOR:FORMICA CORPORATION, A CORP. OF DE;REEL/FRAME:005208/0439 Effective date: 19890907 |